Method of Producing Sportsball with Sculptural Ball Surface

Abstract

A sports ball includes a ball body having a valve stem formed thereat, a plurality of carcass panels, a plurality of sculptural bumps is integrally formed on at least a portion of one of the carcass panels to form a sculptural ball surface of the carcass panel, wherein the carcass panels are overlapped on said ball body to form a ball carcass in a stitch-less manner. Accordingly, the sculptural bumps are raised above an outer panel surface of the carcass panel without applying a depression force to indent on the outer panel surface of the carcass panel. The carcass panels are interlocked and bonded with each other edge-to-edge to enclose the ball body inside the ball carcass.

Claims

1. A soccer ball, comprising: a ball body having a valve stem formed thereat; a plurality of carcass panels overlappedly laminated on said ball body to form a ball carcass in a stitch-less manner, wherein said carcass panels are interlocked and bonded with each other edge-to-edge to enclose said ball body inside said ball carcass, wherein one of said carcass panels has a valve hole aligning with said valve stem of said ball body; and a sculptural arrangement having a plurality of sculptural bumps integrally formed on at least a portion of one of said carcass panels to form a sculptural ball surface of said carcass panel that create maximum grip and speed of said soccer ball, wherein said sculptural bumps are raised above an outer panel surface of said carcass panel without applying a depression force to indent on said outer panel surface of said carcass panel.

2. The soccer ball, as recited in claim 1, wherein said sculptural bumps are orderly sculptured in a wavy pattern on said carcass panel, wherein each of said sculptural bumps are sculptured in a quadrilateral shape.

3. The soccer ball, as recited in claim 2, wherein six of said carcass panels are provided to interlock with each other edge-to-edge to form said ball carcass, wherein each of said carcass panels has a X configuration to define a center panel portion and four panel extension portions, wherein each of said carcass panels has a plurality of curved edges and at least a straight edge extended from one of said curved edges, wherein each of said carcass panels comprises a skin layer, a backing layer, and a cushioning layer sandwiched between said skin layer and said backing layer, wherein a design pattern is printed on said skin layer.

4. The soccer ball, as recited in claim 3, wherein said ball body comprises an inflatable bladder and a ball pocket, which is constructed to have a true roundness shape, having an interior cavity receiving said inflatable bladder therein, wherein when said inflatable bladder is inflated, said ball pocket retains a true roundness shape of said inflatable bladder, wherein said ball pocket comprises a plurality of pocket panels which are overlappedly laminated with each other side by side and are treated to form an integral spherical structure of said ball pocket so as to retain a true roundness shape of said inflatable bladder after said inflatable bladder is inflated.

5. The soccer ball, as recited in claim 3, wherein said ball body comprises an inflatable bladder and a ball pocket, which is constructed to have a true roundness shape, having an interior cavity receiving said inflatable bladder therein, wherein when said inflatable bladder is inflated, said ball pocket retains a true roundness shape of said inflatable bladder, wherein said ball pocket comprises an exterior web layer, which is integrally attached on an outer surface of said inflatable bladder, comprising at least an elongated strengthened thread evenly wound around said outer surface of said inflatable bladder such that said web layer embraces said inflatable bladder for resisting stress and impact force applied to said inflatable bladder.

6. The soccer ball, as recited in claim 1, wherein said plurality of sculptural bumps integrally formed on said portion of one of said carcass panels to form said sculptural ball surface of said carcass panel is made by providing a treatment layer placed on top of said carcass panel, wherein said treatment layer comprises a mesh layer having a plurality of meshes thereon, and a sculptural layer formed at a bottom side of said mesh layer, wherein said sculptural layer is made of sculptural substance formed at said bottom side of said mesh layer and filled at said meshes of said mesh layer, wherein said sculptural layer is integrally bonded on said outer panel surface of said carcass panel, such that said sculptural substances filled at said meshes of said mesh layer forms said sculptural bumps on said outer panel surface of said carcass panel respectively, wherein said mesh layer on top of said carcass panel is removed to leave said sculptural layer on said outer panel surface of said carcass panel.

7. The soccer ball, as recited in claim 6, wherein said mesh layer is made of non-stick material, such that said mesh layer is removed after said sculptural layer is applied on said outer panel surface of said ball carcass.

8. The soccer ball, as recited in claim 7, wherein heat is applied on said treatment layer to detach said sculptural layer from said mesh layer and to integrally bond said sculptural layer on said outer panel surface of said carcass panel.

9. The soccer ball, as recited in claim 8, wherein said meshes are orderly formed at said mesh layer in a wavy configuration to sculpture said sculptural bumps in a wavy pattern on said carcass panel, wherein each of said meshes has a quadrilateral shape to to sculpture each of said sculptural bumps with quadrilateral shape.

10. The soccer ball, as recited in claim 1, wherein said plurality of sculptural bumps integrally formed on said portion of one of said carcass panels to form said sculptural ball surface of said carcass panel is made by providing a mesh layer placed on top of said carcass panel, wherein said mesh layer has a plurality of meshes thereon,k wherein a sculptural substance is evenly applied on said mesh layer that said sculptural substance passes through said meshes to be integrally bonded on said outer panel surface of said carcass panel to form said sculptural bumps thereon, wherein said mesh layer is removed on top of said carcass panel.

11. The soccer ball, as recited in claim 10, wherein said sculptural substance is in liquid form when applying on said mesh layer and is in solid form after dried.

12. The soccer ball, as recited in claim 11, wherein said mesh layer is made of non-stick material, such that said mesh layer is removed after said sculptural substance is applied on said outer panel surface of said ball carcass through said meshes.

13. The soccer ball, as recited in claim 10, wherein said sculptural substance on said mesh layer is swept to ensure said sculptural substance to be evenly applied on said mesh layer and to be evenly penetrated through said meshes on said outer panel surface of said carcass panel, and that said sculptural substance which is excessively left on said mesh layer after said sculptural substance is applied on said outer panel surface of said carcass panel is swabbed until said sculptural substance is filled at said meshes of said mesh layer and no said sculptural substance leaves on said mesh layer.

14. The soccer ball, as recited in claim 12, wherein said meshes are orderly formed at said mesh layer in a wavy configuration to sculpture said sculptural bumps in a wavy pattern on said carcass panel, wherein each of said meshes has a quadrilateral shape to sculpture each of said sculptural bumps with quadrilateral shape.

15. The soccer ball, as recited in claim 6, wherein six of said carcass panels are interlocked with each other edge-to-edge to form said ball carcass, wherein each of said carcass panels has a X configuration to define a center panel portion and four panel extension portions, wherein each of said carcass panels has a plurality of curved edges and at least a straight edge extended from one of said curved edges.

16. The soccer ball, as recited in claim 12, wherein six of said carcass panels are interlocked with each other edge-to-edge to form said ball carcass, wherein each of said carcass panels has a X configuration to define a center panel portion and four panel extension portions, wherein each of said carcass panels has a plurality of curved edges and at least a straight edge extended from one of said curved edges.

17. The soccer ball, as recited in claim 1, wherein said carcass panels are adhered on said ball body to form said ball carcass in a stitch-less manner so as to enclose said ball body inside said ball carcass, wherein each of said carcass panels comprises a skin layer, a backing layer, and a cushioning layer sandwiched between said skin layer and said backing layer.

18. The soccer ball, as recited in claim 5, wherein said carcass panels are adhered on said ball body to form said ball carcass in a stitch-less manner so as to enclose said ball body inside said ball carcass, wherein each of said carcass panels comprises a skin layer, a backing layer, and a cushioning layer sandwiched between said skin layer and said backing layer.

19. The soccer ball, as recited in claim 6, wherein said carcass panels are adhered on said ball body to form said ball carcass in a stitch-less manner so as to enclose said ball body inside said ball carcass, wherein each of said carcass panels comprises a skin layer, a backing layer, and a cushioning layer sandwiched between said skin layer and said backing layer.

20. The soccer ball, as recited in claim 14, wherein said carcass panels are adhered on said ball body to form said ball carcass in a stitch-less manner so as to enclose said ball body inside said ball carcass, wherein each of said carcass panels comprises a skin layer, a backing layer, and a cushioning layer sandwiched between said skin layer and said backing layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a perspective view of a sports ball according to a preferred embodiment of the present invention.

[0026] FIG. 2 is a schematic diagram illustrating the manufacturing process of the sports ball according to the above preferred embodiment of the present invention.

[0027] FIG. 3 is a flow diagram illustrating the manufacturing process of the sports ball according to the above preferred embodiment of the present invention.

[0028] FIG. 4 illustrates the formation of the sculptural ball surface of the carcass panel according to the above preferred embodiment of the present invention.

[0029] FIG. 5 illustrates an alternative mode of the formation of the sculptural ball surface of the carcass panel according to the above preferred embodiment of the present invention.

[0030] FIG. 6 illustrates an alternative mode of the ball pocket of the sports ball according to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0031] The following description is disclosed to enable any person skilled in the art to make and use the present invention. Preferred embodiments are provided in the following description only as examples and modifications will be apparent to those skilled in the art. The general principles defined in the following description would be applied to other embodiments, alternatives, modifications, equivalents, and applications without departing from the spirit and scope of the present invention.

[0032] Referring to FIGS. 1 to 3 of the drawings, a sports ball and its manufacturing method thereof according to a preferred embodiment of the present invention is illustrated, wherein the sports ball is shown as a soccer ball as an example. The sports ball comprises a ball body 10, a plurality of carcass panels 20, and a sculptural arrangement 30.

[0033] The ball body 10, having a valve stem 101 formed thereat, comprises an inflatable bladder 11 and a ball pocket 12, which is constructed to have a true roundness shape, having an interior cavity receiving the inflatable bladder 11 therein, wherein when the inflatable bladder 11 is inflated, the ball pocket 12 retains a true roundness shape of the inflatable bladder 11.

[0034] Accordingly, the ball pocket 12 comprises a plurality of ball pocket leaves 121 integrally connected with each other. Practically, the fabric made ball pocket 12 is able to form a spherical body that the ball pocket 12 is constructed to have a true roundness shape so as to retain a maximum diameter of the inflatable bladder 11 after it is inflated.

[0035] The ball pocket 12 is preferred to be made of fabric material having a durability, stretchability and adhesiveablility. Preferably, the ball pocket 12 can be made of a mixture fabric mixed with cotton and polyester because the cotton has a good stretchability and is able to absorb adhesive material and the polyester is durable and has a strong strength that is able to resist strain when the inflatable bladder 11 is inflated.

[0036] The inflatable bladder 11 is disposed in the ball pocket 12 which has a size slightly bigger than the inflatable bladder 11 in such a manner that when the inflatable bladder 11 is inflated, an outer spherical surface of the inflatable bladder 11 is preferred to be slightly spaced apart from an inner spherical surface of the ball pocket 12 to form an air cushion layer therebetween. The air cushion layer is adapted for providing a cushion effect for the stitching ball to provide a softness for the stitching ball and tolerate heavier impact thereon.

[0037] The carcass panels 20 are overlappedly laminated on the ball body 10 to form a ball carcass in a stitch-less manner, wherein the carcass panels 20 are interlocked and bonded with each other edge-to-edge to enclose the ball body 10 inside the ball carcass, wherein one of the carcass panels 20 has a valve hole 201 aligning with the valve stem 101 of the ball body 10.

[0038] The sculptural arrangement 30 has a plurality of sculptural bumps 31 integrally formed on at least a portion of one of the carcass panels 20 to form a sculptural ball surface of the carcass panel 20 that create maximum grip and speed of the sports ball, wherein the sculptural bumps 31 are raised above an outer panel surface of the carcass panel 20 without applying a depression force to indent on the outer panel surface of the carcass panel 20.

[0039] Accordingly, the method of manufacturing a sports ball comprises the following steps.

[0040] (1) Provide the ball body 10.

[0041] (2) Provide a plurality of carcass panels 20. Preferably, only six carcass panels 20 are provided to form the soccer ball.

[0042] (3) Integrally form the sculptural bumps 31 on at least a portion of one of the carcass panels 20 to form the sculptural ball surface of the carcass panel 20.

[0043] (4) Overlap the carcass panels 20 on the ball body 10 to form the ball carcass in a stitch-less manner. Preferably, the carcass panels 20 are laminated on the ball body 10 to form the ball carcass in a stitch-less manner. Accordingly, the ball carcass is vulcanized to form an integral spherical carcass around the ball body 10 to provide a cushion effect for the sports ball at any point thereof. Note that the heat treatment (vulcanization) can be performed by conventional heating machine, such as a vulcanizing machine.

[0044] It is worth mentioning that the edge portion of each of the carcass panels 20 is slanted that a top surface of the edge portion of the carcass panel 20 downwardly and inclinedly extends a bottom surface thereof. Therefore, when the carcass panels 20 are attached onto the ball body 10 edge-to-edge, the edge portions of the two adjacent carcass panels 20 form an indented channel on the ball carcass. In other words, the edge portions of the adjacent carcass panels 20 form the beveled seams for the carcass panels 20 attaching onto the ball carcass edge-to-edge. Preferably, the edge portion of the carcass panel 20 is trimmed to form the slanted edge portion. Alternatively, the ball carcass is pressed in a mold along the edge portions of the carcass panels 20 to form the indented channels on the ball carcass.

[0045] In order to manufacture the ball body 10, the step (1) further comprises the following steps.

[0046] (1.1) Form the ball pocket 12, which is constructed to have a true roundness, having the interior cavity. The ball pocket 12 is made by the steps of:

[0047] (1.1.1) providing a parent bladder having a true roundness shape after the parent bladder is inflated, wherein the parent bladder has the same size and shape of the inflatable bladder 11;

[0048] (1.1.2) overlapping a plurality of pocket panels 121 on the parent bladder at a position that edge portions of the pocket panels 121 are overlapped with edge portions of the adjacent pocket panels 121, wherein one of the pocket panels 121, having a valve hole, is remained unattached to form an inlet opening of the ball pocket 12;

[0049] (1.1.3) heat-treating the pocket panels 121 to integrally bond the ball panels 121 together to form a hollow round pocket body having the inlet opening provided thereon; and

[0050] (1.1.4) removing the parent bladder from the hollow round pocket body through the inlet opening after the parent bladder is deflated, so as to form the ball pocket 12.

[0051] (1.2) Dispose the inflatable bladder 11 in the ball pocket 12, wherein when the inflatable bladder 11 is inflated, the ball pocket 12 retains a true roundness shape of the inflatable bladder 11. It is worth mentioning that after the inflatable bladder 11 is disposed in the ball pocket 12 through the inlet opening thereof, the inlet opening is sealed by attaching the unattached pocket panel 121 at a position that the valve hole 201 is aligned with the valve stem 101 to sealedly enclose the interior cavity to form the ball body 10.

[0052] FIG. 6 illustrates an alternative mode of forming the ball pocket 12 which comprises an exterior web layer 121, which is integrally attached on an outer surface of the inflatable bladder 11, and comprising at least an elongated strengthened thread 122 evenly wound around the outer surface of the inflatable bladder 11 such that the web layer 121 embraces the inflatable bladder 11 for resisting stress and impact force applied to the inflatable bladder 11. In order to enable the strengthened threads 122 being permanently affixed on the outer surface of the inflatable bladder 11, before winding onto the inflatable bladder 11, the strengthened threads 122 are coated with glue for adhering onto the outer surface of the inflatable bladder 11 and each other. Moreover, the inflatable bladder 11 with the adhering strengthened threads 122 thereon are together cured by heating in a mold, so that the adhering strengthened threads 122 will be hardened to form the exterior web layer 121 which is permanently united with the inflatable bladder 11 integrally.

[0053] Accordingly, the step (1.1) further comprises the steps of:

[0054] (1.1.1) applying adhesive along the strengthened threads 122;

[0055] (1.1.2) evenly winding at least an elongated strengthened thread 122 around the outer surface of the inflatable bladder 11 to form the web layer 121, such that the web layer 121 embraces the inflatable bladder 11 for resisting stress and impact force applied to the inflatable bladder 11; and

[0056] (1.1.3) hardening the strengthened threads 122 by heat to form the exterior web layer 121 which is permanently united with the inflatable bladder 11 integrally.

[0057] As it is mentioned above, there are six carcass panels 20 overlappedly laminated on the ball body 10 to form the ball carcass in a stitch-less manner. In particular, the carcass panels 20 are interlocked and bonded with each other edge-to-edge to enclose the ball body 10 inside the ball carcass.

[0058] According to the preferred embodiment, the step (2) further comprises a step of cutting the carcass panel 20 into a predetermined shape. Each of the carcass panels 20 has a X configuration to define a center panel portion 21 and four panel extension portions 22 outwardly extended from the center panel portion 21. Each of the carcass panels 20 further has a plurality of curved edges 23 and at least a straight edge 24 extended from one of the curved edges 23. In particular, at least one curved edge 23 and at least one straight edge 24 are formed at each of the panel extension portions 22 of the carcass panels 20.

[0059] Having the X configuration of the carcass panel 20 with the curved and straight edges 23, 24, minimum numbers of carcass panel 20 can be used to form the ball carcass not only for simplifying the manufacturing process of the sports ball but also for enhancing the true roundness for the sports ball at any point thereof. It is worth mentioning that the curved edges 23 and the straight edges 24 of the carcass panels 20 are aligned with each other to interlock the carcass panels 20.

[0060] Furthermore, the step (2) further comprises the steps of:

[0061] (2.1) providing a cushioning layer 25, wherein the cushioning layer 25 is made of foam material provide a uniform cushion effect to the sports ball for ensuring uniform performance thereof when the sports ball is actually in use in a ball game;

[0062] (2.2) attaching a skin layer 26 on the top side of the cushioning layer 25, wherein the skin layer 26 is made of durable and waterproof material, such as rubber; and

[0063] (2.3) attaching a backing layer 27 at the bottom side of the cushioning layer 25 to form the carcass panel 20. Accordingly, the backing layer 27 can be made of fabric to enhance the strength of the carcass panel 20 and to ensure the carcass panel 20 to be laminated on the ball body 10. In other words, the cushioning layer 25 is sandwiched between the skin layer 26 and the backing layer 27.

[0064] In addition, the step (2) further comprises a step of forming a logo and/or design pattern on the skin layer 26. Accordingly, the logo and/or design pattern in different colors can be coated or printed on the skin layer 26. It is worth mentioning that the skin layer 26 provides a flat and smooth surface, such that the logo and/or design pattern can be easily printed on the skin layer 26. Preferably, the logo and/or design pattern can be coated on the skin layer 26 by screen printing. For example, ink is forced to pass through a screen stencil to coat the ink on the skin layer 26 in order to form the logo and/or design pattern.

[0065] As shown in FIG. 4, in order to form the sculptural ball surface of the carcass panel 20, the step (3) further comprises the following steps.

[0066] (3.1) Place a treatment layer 40 on top of the carcass panel 20, wherein the treatment layer 40 comprises a mesh layer 41 having a plurality of meshes 411 thereon, and a sculptural layer 42 formed at a bottom side of the mesh layer 41. In particular, the sculptural layer 42 is made of sculptural substance, such as adhesive, formed at the bottom side of the mesh layer 41 and filled at the meshes 411 of the mesh layer 41.

[0067] Accordingly, the mesh layer 41 is a thin film made of non-stick material. The sculptural layer 42 also is a thin film overlapped at the bottom side of the mesh layer 41 to define a film portion at the bottom side of the mesh layer and a plurality of protruded portions filled at the meshes 411 of the mesh layer 41. In other words, the thickness of each of the protruded portions of the sculptural layer 42 is larger than the thickness of the film portion of the sculptural layer 42. The thickness of each of the protruded portions of the sculptural layer 42 is the total thickness of the film portion of the sculptural layer 42 and the thickness of the mesh layer 41.

[0068] (3.2) Integrally bond the sculptural layer 42 on the outer panel surface of the carcass panel 20, such that the sculptural substances filled at the meshes 411 of the mesh layer 41 forms the sculptural bumps 31 on the outer panel surface of the carcass panel 20 respectively. Preferably, heat is gently applied onto the treatment layer 40 to detach the sculptural layer 42 from the mesh layer 41 and to integrally bond the sculptural layer 42 on the outer panel surface of the carcass panel 20. As shown in FIG. 4, a heater with an elongated heater head is reciprocatingly moved on the treatment layer 40 in order to evenly apply the head on the treatment layer 40. Once the sculptural substance is heated, the sculptural layer 42 will be detached from the mesh layer 41 and will be integrally bonded on the outer panel surface of the carcass panel 20. It is worth mentioning that relatively low heat, preferably 40-50 C., is applied onto the treatment layer 40.

[0069] The sculptural substance is preferably PU composite ink to be formed on the bottom side of the mesh layer 41, such that the sculptural layer 42 will form a clear coat on the outer panel surface of the carcass panel 20. It is worth mentioning that the sculptural substance can be transparent or configured with a desired color to be coated on the outer panel surface of the carcass panel 20.

[0070] (3.3) Remove the mesh layer 41 on top of the carcass panel 20 to leave the sculptural layer 41 on the outer panel surface of the carcass panel 20. Accordingly, once the sculptural layer 42 is integrally bonded on the outer panel surface of the carcass panel 20, the non-stick mesh layer 41 can be easily removed from the sculptural layer 42, such that the sculptural substances, which are previously filled at the meshes 411 of the mesh layer 41, will integrally protrude out from the outer panel surface of the carcass panel 20 so as to form the sculptural bumps 31 on the outer panel surface of the carcass panel 20 respectively.

[0071] According to the preferred embodiment, the sculptural bumps 31 can be evenly formed on the entire outer panel surface of the carcass panel 20, such that the entire outer panel surface of the carcass panel 20 will form the sculptural ball surface. It should be appreciated that the sculptural bumps 31 can be only formed on a portion of the outer panel surface of the carcass panel 20, such as only the logo thereon, such that only the logo surface will form the sculptural ball surface. It is worth mentioning that the sculptural layer 42 also serves as a protection layer to protect the logo and/or design pattern on the skin layer 26 of the carcass panel 20.

[0072] As shown in FIG. 4, the meshes 411 are orderly formed at the mesh layer 41 in a wavy configuration to sculpture the sculptural bumps 31 in a wavy pattern on the carcass panel 20. Furthermore, each of the meshes 411 has a quadrilateral shape to sculpture each of the sculptural bumps 31 with quadrilateral shape. It should be appreciated that the sizes and shapes of the meshes 411 can be changed to sculpture different sculptural bumps 31 in different patterns and different shapes. For example, each of the sculptural bumps 31 can have a semi-spherical shape protruded out of the outer panel surface of the carcass panel 20. It is worth mentioning that the sculptural bumps 31 are formed by the sculptural substances, wherein no depression force is required for applying on the outer panel surface of the carcass panel 20 in order to indent the outer panel surface of the carcass panel 20. In other words, there is no damage on the outer panel surface of the carcass panel 20 in order to form the sculptural ball surface.

[0073] FIG. 5 illustrates an alternative method to form the sculptural ball surface, wherein the step (3) comprises the following steps.

[0074] (3.1) Place a mesh layer 41 on top of the carcass panel 20, wherein the mesh layer 41 has a plurality of meshes 411 thereon.

[0075] (3.2)Evenly apply a sculptural substance 42 on the mesh layer 41 that the sculptural substance 42 passes through the meshes 411 to be integrally bonded on the outer panel surface of the carcass panel 20 to form the sculptural bumps 31 thereon. Accordingly, the sculptural substance 42 is in liquid form when applying on the mesh layer 41 and is in solid form after dried. In other words, the fluid sculptural substance 42 is directly applied on the mesh layer 41 such that the fluid sculptural substance 42 will fill into the meshes 411 and will contact with the outer panel surface of the carcass panel 20. Once the fluid sculptural substances 42 at the meshes 411 are dried, the fluid sculptural substances 42 will integrally bond on the outer panel surface of the carcass panel 20 to form the sculptural bumps 31 thereon.

[0076] The sculptural substance 42 is preferably PU composite ink to be applied on the outer panel surface of the carcass panel 20, such that the sculptural substance 42 will form a clear coat on the outer panel surface of the carcass panel 20. It is worth mentioning that the sculptural substance 42 can be transparent or configured with a desired color to be coated on the outer panel surface of the carcass panel 20.

[0077] Accordingly, the sculptural substance 42, such as the PU composite ink, is coated on the outer panel surface of the carcass panel 20 by screen printing. In other words, the mesh layer 41 serves as a screen stencil to enable the sculptural substance 42 to pass through the meshes 411 and to apply on the outer panel surface of the carcass panel 20. Preferably, the sculptural substance 42 is sprayed on the mesh layer 41 via a spraying head to evenly apply the sculptural substance 42 on the mesh layer 41 to the outer panel surface of the carcass panel 20.

[0078] The step (3.2) further comprises the following steps.

[0079] (3.2.1) Sweep the sculptural substance 42 on the mesh layer 41 to ensure the sculptural substance 42 to be evenly applied on the mesh layer 41 and to be evenly penetrated through the meshes 411 on the outer panel surface of the carcass panel 20. Accordingly, a sweeper having an elongated sweeping head is reciprocatingly moved on the mesh layer 41 to evenly apply the sculptural substance 42 on the mesh layer 41 and to ensure the sculptural substance 42 to be filled at the meshes 411 of the mesh layer 41.

[0080] (3.2.2) Swab excessive sculptural substance on the mesh layer 41 after the sculptural substance 42 is applied on the outer panel surface of the carcass panel 20. Once the sculptural substances 42 are filled at the meshes 411 of the mesh layer 41, the sweeping head can reciprocatingly move on the mesh layer 41 to swab excessive sculptural substance on the mesh layer 41. Accordingly, the sweeping and swabbing actions in the steps (3.2.1) and (3.2.2) can be repeatedly preformed until the sculptural substances 42 are filled at all the meshes 411 of the mesh layer 41 and no excessive sculptural substance leaves on the mesh layer 41.

[0081] (3.3)Remove the mesh layer 41 on top of the carcass panel 20. Accordingly, the non-stick mesh layer 41 can be easily removed from the sculptural substances 42, such that the sculptural substances 42, which are previously filled at the meshes 411 of the mesh layer 41, will integrally protrude out from the outer panel surface of the carcass panel 20 so as to form the sculptural bumps 31 on the outer panel surface of the carcass panel 20 respectively.

[0082] Furthermore, heat can be gently applied onto the carcass panel 20 to integrally bond the sculptural substances 42 on the outer panel surface of the carcass panel 20. It is worth mentioning that relatively low heat, preferably 40-50 C., is applied onto the sculptural substance 42 in order to integrally bond the sculptural substance 42 on the outer panel surface of the carcass panel 20.

[0083] Likewise, the meshes 411 are orderly formed at the mesh layer 41 in a wavy configuration to sculpture the sculptural bumps 31 in a wavy pattern on the carcass panel 20. Furthermore, each of the meshes 411 has a quadrilateral shape to sculpture each of the sculptural bumps 31 with quadrilateral shape. It should be appreciated that the sizes and shapes of the meshes 411 can be changed to sculpture different sculptural bumps 31 in different patterns and different shapes. It is worth mentioning that the sculptural bumps 31 are formed by the sculptural substances, wherein no depression force is required for applying on the outer panel surface of the carcass panel 20 in order to indent the outer panel surface of the carcass panel 20. In other words, there is no damage on the outer panel surface of the carcass panel 20 in order to form the sculptural ball surface.

[0084] Accordingly, thousands of sculptural bumps 31 can be integrally protruded from the outer surface of the ball carcass, i.e. all the outer panel surfaces of the carcass panels 20, to substantially increase the surface friction of the sports ball so as to maximize the gripping ability of the sports ball. Therefore, the player, such as the soccer player, is able to easily control the sports ball and to accurately shoot the sports ball. In addition, an air channel is formed between the sculptural bumps 31 to enhance the aerodynamics of the sports ball. In particular, the wavy configuration of the sculptural bumps 31 will create the wavy air channel to enhance the speed of the sports ball, especially when the sports ball is spinning. It is worth mentioning that the sculptural bumps 31 are relatively light weight, such that the overall weight of the sports ball will be determined without taking into account of the weight of the sculptural bumps 31. Furthermore, the size of the sculptural bump 31 is adjustably controlled by the dimension, such as the depth, of the meshes 411, 411 of the mesh layer 41, 41.

[0085] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

[0086] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.